Ford ranger 2012 Mounting Manual
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Ford ranger 2012 Mounting Manual

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Body and Equipment Mounting Manual
FORD RANGER 2012
Date of Publication: 12/2014

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  • Page 1 Body and Equipment Mounting Manual FORD RANGER 2012 Date of Publication: 12/2014...
  • Page 2 This publication, or part thereof, may not be reproduced nor translated without our approval. Errors and omissions excepted. © Ford Motor Company 2014 All rights reserved.

  • Page 3: Table Of Contents

    How to Use This Manual......5 2.2.2 Brake Hoses..........31 Commercial and Legal Aspects..6 2.2.3 Trailer brakes..........31 1.2.1 Terminology............6 1.2.2 Warranty on Ford Vehicles.......6 1.2.3 Legal and Vehicle Type Approval...6 1.2.4 Alternative Type Approval......6 3 Powertrain 1.2.5 Legal Obligations and Liabilities....6 1.2.6 General Product Safety Requirement..........6...
  • Page 4 5.1.7 Bull Bar (Vehicles with Special Equipment Pack)........70 5.1.8 Roof Racks............71 5.1.9 Canopies............72 Airbag Supplemental Restraint System (SRS)........75 5.2.1 Air Bags............75 5.2.2 Supplementary Restraint Sensors (Front).............78 Safety Belt System......79 Corrosion Prevention......80 5.4.1 General............80 5.4.2 Repairing Damaged Paint.......80 5.4.3 Under Body Protection and Material............80 5.4.4 Painting Road Wheels......80...

  • Page 5: About This Manual

    These requirements must be complied multiple steps. If the warning, caution or note only with before a Ford Dealer should take delivery of applies to one step, it is placed at the beginning motor vehicle accessories from an external of the specific step (after the step number).

  • Page 6: Commercial And Legal Aspects

    Ford vehicle or component roads. The Vehicle Converter shall also ensure that does not reduce the safety, function, or durability any alteration it makes to a Ford vehicle or of the vehicle or any component. component does not reduce its compliance with The Vehicle Converter shall be solely responsible local design rules.

  • Page 7: Product Liability

    Ford vehicle or component made by the Vehicle Converter or any of its agents. Ford shall not be liable for any such liability (except as 1.2.10 Minimum Requirements for Brake system and Load Apportioning provided by law).

  • Page 8: Conversion Homologation

    • The fixing of the body to the donor vehicle. • Operating conditions. The responsible Technical Service may require additional information and/or testing. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 9: Electromagnetic Compatibility (Emc)

    Antenna Position (Peak RMS) 1-30 30-54 68-87.5 142-176 380-512 806-940 806-940 1200-1400 1710-1885 1710-1885 1885-2025 1885-2025 2400-2500 Anywhere * Only for GSM/3G cellular phones, with a patch antenna installed inside of the front windscreen. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 10: Suggested Antenna Location

    • With the engine running. • During a road test at various speeds. Check that electromagnetic fields generated inside the vehicle cabin by the transmitter installed do not exceed human exposure limits specified in EU directive 2004/40/EC. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 11: Vehicle Duty Cycle Guidelines

    Where possible make sure that the base vehicle is ordered with any necessary plant fit options. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. 1.5.1 Conversion Affect on Fuel Economy and Performance Any conversion may effect the fuel consumption and performance depending on the aerodynamics and the weight added by the conversion.

  • Page 12: Jacking

    5. No person should place any portion of their literature included with the owner's body under a vehicle that is supported by a jack. documentation. All Vehicles E133942 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 13: Lifting

    It is important that only the correct lifting and support locations are used at all times. All Vehicles E133943 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 14: Noise, Vibration And Harshness (Nvh)

    The interior noise levels should not be deteriorated by the conversion. Reinforce panels and structures as appropriate to avoid vibrations. Consider the usage of sound deadening material on panels. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 15: Vehicle Transportation Aids And Vehicle Storage

    Check vehicle is Claims arising from deterioration caused by clean incorrect storage, maintenance or handling are not the responsibility of Ford. Remove external contamination Vehicle Converters must determine their own procedures and precautions, particularly where Check battery...

  • Page 16: Package And Ergonomics

    Rear view mirror is homologated up to 1880 mm WARNING: Ensure that monitors mounted in the cabin meet the interior package and maximum body width, see the Figure below, dimension 'X'. safety requirements. E134151 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 17: Package And Ergonomics Specifications

    Body gravity of the body and payload does not fall attachment points are provided on the frame. outside of the recommended zone. Refer to: 5.1 Body (page 65). Refer to: 1.13 (page 23). Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 18 Chassis Cab Body - Single Cab Illustrated E134142 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 19 Maximum external body width 1880 All dimensions (shown in mm) are subject to manufacturing tolerances and refer to min specification models which do not include additional equipment. The illustrations are for guidance only. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 20: Chassis Cab Body - Basic Dimensions And Weights

    1.11.2 Chassis Cab Body - Basic Dimensions and Weights Chassis Cab Body - Single Cab Illustrated E134164 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 21: Kerb Weights And Payload

    1.11.4 Front, Rear and Side Under-run Protection WARNING: Check local legislation for legal requirements. Front Under run Protection, Rear Under run Protection and Side Under run Protection must meet the requirements of local design rules. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 22: Hardware Specifications

    317.5 399.4 345.0 430.0 434.7 541.8 470.0 590.0 592.2 743.4 600.0 750.0 756.0 945.0 This torque chart is a recommendation and the converter is responsible for the optimal torque for a specific joint. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 23: Load Distribution-Specifications

    NOTE: Avoid one-sided load distribution. maintained. NOTE: For further information please contact NOTE: Uneven load distribution could result in your local National Sales Company representative, unacceptable handling and braking or Local Ford Dealer. characteristics. Single Cab E133921 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 24 'A' Wheelbase 'B' Front row 'C' Second row Weight distribution per person (Kg) (mm) seats and seats (mm) driver (mm) On Front Axle On Rear Axle Total 3220 1490 2310 Stretch Cab E133925 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 25: Center Of Gravity

    Single Cab Center of Gravity Critical Zone Model Recommended C of G location for added mass 'A' Min (mm) 'B' Max (mm) 'C' Max (mm) 1965 3220 1965 3435 1965 3435 Vehicles with increased ride height. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 26 Recommended C of G location for added mass Max gross added mass (kg) 'A' Min (mm) 'B' Max (mm) 'C' Max (mm) 2585 3615 2435 3615 2435 3615 Vehicles with increased ride height. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 27 Stretch Cab Center of Gravity Critical Zone Model Recommended C of G location for added mass 'A' Min (mm) 'B' Max (mm) 'C' Max (mm) 2395 3220 2365 3435 2365 3435 Vehicles with increased ride height. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 28: Towing

    When a towing device is required, the Vehicle • Any modifications to the vehicle must be noted Converter should use a Ford approved tow bar. in the owner's handbook or new descriptive literature included with the owner's Refer to: 1.13 (page 23).

  • Page 29: Trailer Nose Weight

    European vehicles built on or after 11th March 2013 and Australia and New Zealand vehicles built on or after 1st November 2012. 1.14.4 Trailer Nose Weight NOTE: The maximum trailer nose weight values below relate to vehicles with Ford tow bars only. Trailer Nose Weight Region / Vehicle Minimum trailer nose...

  • Page 30: Suspension System

    Adding or removing leaves may result in failure or reduced function of the spring as well as other vehicle related issues for which Ford Motor Company can not be held responsible. CAUTIONS: Modifications to the suspension system can cause a deterioration of the vehicle handling characteristics and durability.

  • Page 31: Brake System

    CAUTION: Make sure that the front and rear brake hoses are not twisted and are correctly located away from body and chassis components. E201170 Brake Light Circuit Feed Item Description Brake Pedal +12V when brake pedal is pressed Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 32: Fuel System

    Fuel Filler Pipe Shipping Bracket - Single Cab E145838 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 33 Fuel Filler Pipe Shipping Bracket - Stretch Cab E145839 Fuel Filler Pipe Shipping Bracket - Double Cab E145837 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 34: Fuel Filler Mounting

    E145833 Fuel Filler Mounting Notes Item Description 180 mm minimum at the area must be adhered to above the filler neck All 3x hardware fixation points on the filler neck must be utilised Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 35 Angle of Filler Neck E145836 Filler Neck Installation Dimensions Item Description 2mm minimum bracket thickness 30° Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 36 Clearance From Vehicle Body E145835 Item Description At least 9mm clearance between the fuel filler cap and vehicle body, in the worst case opening angle if applicable Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 37: Fuel Filler Vent Hose

    • The fuel tank vent hose should be protected and positioned away from direct water spray, wheel splash and mud splash. • The fuel tank vent hose must be pointing in a downward direction. E170965 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 38 E171721 Item Description Front lower head board of the aluminium load tray (load tray rotated for clarity) Rear of the passenger cabin (cabin back panel) Underside of the pick up box load tray Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 39: Battery And Cables

    • Carry out a two hour charge using 20A constant current (manual setting on charger). • Carry out a two hour charge using a constant potential (automatic setting on charger). Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 40 Redarc (or similar) and ground it to the vehicle body. Ford Ranger vehicles are equipped with a new 2. Request a Ford dealer to disable the BMS. feature called Battery Monitor System (BMS). This Disabling the BMS enables voltage sensitive system measures the battery load in order to relay based dual battery systems to work.

  • Page 41: Auxiliary Battery (Vehicles With Special Equipment Pack)

    • For external charging of batteries ensure that to determine that the electrolyte (acid) the maximum voltage of 14.6V is not exceeded. levels are correctly maintained. 4.1.2 Auxiliary Battery (Vehicles with Special Equipment Pack) Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 42 E179834 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 43 E179835 Item Description Auxiliary battery ground point Battery cable (towards main battery) Auxiliary battery carrier mounting bolts Auxiliary battery fuse box Auxiliary battery Temporary battery carrier Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 44 NOTE: Avoid damage to the vehicle and the load where the auxiliary battery is relocated, tray during the auxiliary battery fitment. consideration must be made as to the routing and security of the auxiliary battery cable location. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 45: Auxiliary Battery Relocation And Use Of Electrical Harness Extension (Fly Lead) (Vehicles With Special Equipment Pack)

    16-pin connector on the vehicle wiring harness. This allows the operation of auxiliary battery powered accessories from the dash mounted switch panel within the vehicle cabin. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 46: Generator And Alternator

    E201186 Item Description Electrical Harness Extension (fly lead) Connection to the vehicle harness Connection to the auxiliary wiring harness 4.1.4 Generator and Alternator Alternator Current Output All vehicles are fitted with 110A alternators. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 47: Electronic Engine Controls

    50% +/- 10% Frequency 1.38 * v (Vehicle speed (CAN) km/h) ± 2% between 1km/h - 250km/h Minimum speed 1.38 Hz (1 kmph) Linearity error <0.3% Max frequency 398 Hz Rload 1 k ohms Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 48 2. Once the connector C3 or C4 is removed, the grey cap needs to be removed by first removing the cable tie, and then levering up the two detents on the sides; the cap can then be slid off. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 49 E180283 E180284 E180285 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 50 E180287 4. Insert the wire with terminal into cavity C3: 52 or C4: 3 there is a tab on the terminal that should allow this to be inserted one way only. E180293 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 51 5. Slide back the terminal latching plate, refit the plug both connectors back into the BCM. Refit grey cap (and refit cable tie as required), and any shields/covers. E180294 E180295 E180296 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 52: Exterior Lighting

    Where fitted, these lamps must be requirements. mounted in accordance with the following guidelines. 4.3.1 Rear Combination lamps Positioning of Rear Combination Lamps E141460 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 53: Rear Fog Lamp

    Maximum distance from outer edge of vehicle to inner edge of 400mm lamp 4.3.2 Rear Fog Lamp NOTE: Where only one rear fog lamp is fitted, it must be positioned on the vehicle centre line, or to the drivers side of the vehicle. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 54 Minimum angle of obstruction free zone upwards of the lamp 5° Minimum angle of obstruction free zone towards the outside of the 25° vehicle Minimum angle of obstruction free zone towards the centre of the 25° vehicle Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 55: Rear License Plate Lamp

    Distance between top of rear face of license plate and lamp 35mm mounting face Distance between license plate centre line and centre of lamp 175mm Distance between license plate centre line and centre of lamp 175mm Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 56: Reversing Lamps

    4.3.5 Additional External Lamps be provided via a relay energised by the headlamp feed. When installing auxiliary tail lamps, Ford recommends that power is provided via the trailer plug control module and associated circuitry. Refer to Trailer Tow for additional information.

  • Page 57: Additional External Lamps (Vehicles With Special Equipment Pack)

    For vehicles fitted without a tow bar as standard, flicker when in use. A trailer patch harness should a genuine Ford accessory trailer tow electrical kit be used with low power LED lamps. has been developed to enable a tow bar to be CAUTION: Do not connect the trailer installed.
  • Page 58 E175900 Item Description U nuts NOTE: Cut out the switch blanks with a suitable tool without damaging the plastic fascia. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 59 Once the vehicle is running the isolator will close allowing the auxiliary battery to be charged by the vehicles charging system. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 60 Driving Light Connector Location E183105 Item Description Sealing end-cap Driving light connector NOTE: The light switch connector is located behind the switch fascia in the vehicle. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 61 Switch Panel Connector E175902 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 62 Connections for the load box lamps, LED Beacon lamp and driving lights are provided by a 16 way connector located at the rear of the auxiliary battery box below the isolator. The connector details are as follows. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 63 Fuse Amp Rating Protected Components Driving lights Position lamp LED beacon lamp Work lights Spare Power point Reversing lamp Direction indicators, stop lamp Crew chief Disable fuse (isolator ground) Not used Not used Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 64: Lamps Hazard / Direction Indication

    WARNING: Do not tamper with the base system (controlled by Central Junction Box and multiplex architecture) and any feeds taken from the associated wiring or controller. NOTE: These options are not suitable for aftermarket or Body Builder fit. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 65: Body

    • Re-paint metal edges after cutting or drilling. All metal edges must comply with exterior and interior protection legislation. • All fixings through the floor, sides or roof must be sealed. Wheelhouse Envelope E134132 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 66: Chassis Cab

    NOTE: The following chassis frame images and alterations or additional structure disperse the dimensions are showing the previous Ranger (J97) load evenly. chassis frame above the new Ranger (P375) chassis frame for comparison purposes. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 67 Body Attachment Holes in Chassis Frame - Single cab E134152 E134152 Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab Dimension P375 Dimension P375 1086 1244 1244 1244 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 68 Body Attachment Holes in Chassis Frame - Double cab E134154 E134154 Dimensions (mm) for Body Attachment Holes in Chassis Frame - Double cab Dimension P375 Dimension P375 1086 1244 1244 Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 69: Front End Integrity For Cooling, Crash, Aerodynamics And Lighting

    Static & Dynamic Sealing and Finishing Ensure Crash, Aerodynamics and Lighting proper sealing against ingress of water, salt, dust etc. after cutting or drilling the body. Use Ford approved sealing and finishing material, and Cooling Continuous air flow through the front underbody corrosion protection.

  • Page 70: Tank And Dry Bulk Carriers

    Due to the high rigidity of tanks it is necessary to isolate the tank and its sub-frame from the chassis frame allowing the chassis frame to naturally flex. Please refer to the following guidelines: Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 71: Roof Racks

    There is a service nib provided on the grommet. Refer to Exterior lighting - Additional external lamps for driving lights cable routing. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 72: Canopies

    Ensure that the planned loaded vehicle operates within its designed Center of Gravity condition. For The forgoing limitations are based on ensuring details please consult the Ford dealer. body structure integrity, vehicle handling, braking and plated axle weights. Such considerations must...
  • Page 73 Front structural attachment points Centre structural attachment points Rear structural attachment points Top surface of load box sides Return flange of load box sides Do not cut, drill, or use these surfaces to bolt the canopy. Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 74 Example of a Sports Bar Fitment E172331 Item Description Front mounting bracket Clamped attachment Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 75: Airbag Supplemental Restraint System (Srs)

    Drilling or grinding operations in this area are only permitted when battery cables are disconnected. Driver and Passenger Front Airbag Deployment Zones E134101 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 76 Dimensions (mm) Side Airbag E134609 Dimensions (mm) Curtain Airbag - Single cab E136172 Date of Publication: 12/2014 FORD RANGER 2012...
  • Page 77 Dimensions (mm) Curtain Airbag - Double cab E134610 Dimensions (mm) Curtain Airbag - Stretch cab E136173 Dimensions (mm) Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 78: Supplementary Restraint Sensors (Front)

    5.2.2 Supplementary Restraint WARNING: Modifications or Sensors (Front) reinforcements in the area of the front supplementary restraint sensors may affect their operation. E201479 Item Description Front SRS Impact Sensors Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 79: Safety Belt System

    Do not attempt to release the retractor by pulling on the webbing with significant force or by manually interfering with the locking mechanism. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 80: Corrosion Prevention

    5.4.2 Repairing Damaged Paint After cutting or reworking any sheet metal on the vehicle the damaged paint must be repaired. Ensure all materials are compatible with the relevant Ford specifications and maintain the original performance where possible. 5.4.3 Under Body Protection and Material...

  • Page 81: Frame And Body Mounting

    5. Deburr holes after drilling to fit bolts or rivets. structure where appropriate, to avoid excessive Chamfer 1.0mm x 45 degree on the bolt head load concentrations. side of the hole to facilitate bolt seating. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 82: Self-Supporting Body Structure

    • Out-rigger moment to be re-acted with extended frame. cross-member between chassis frame with Alternatively, the self-supporting body structure common through bolts where possible. can also be designed as shown in figure shown. Date of Publication: 12/2014 FORD RANGER 2012...

  • Page 83: Frame Drilling And Tube Reinforcing

    • Drill frame and add spacer tubes. Drilling and welding of frames and body structure have to be conducted following the program Refer to: 5.5 Frame and Body Mounting (page guidelines. Please consult the Ford dealer for 81). details. • Out-rigger outboard ends should be attached to load bearing body side / floor edge frame or 5.5.4 Ancillary Equipment - Sub Frame...
  • Page 84 About This Manual............5 General...............31, 80 Additional External Lamps........56 General Component Package Guidelines.....16 Additional External Lamps (Vehicles with Special General...............31, 80 Equipment Pack)............57 General Product Safety Requirement......6 Aids for Vehicle Entry and Exit........16 Generator and Alternator...........46 Bags................75 Airbag Supplemental Restraint System (SRS)................75 Hardware—Specifications..........22 Alternative Type...
  • Page 85 Under Body Protection and Material....80 Vehicle Duty Cycle Guidelines........11 Vehicle Ride and Handling Attributes.....11 Vehicle Speed Output (Signal).......47 Vehicle Transportation Aids and Vehicle Storage................15 Warnings, Cautions and Notes in This Manual................5 Warranty on Ford Vehicles..........6 Water Tank on Camper Vehicles......83...

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